Heavy Duty Gear Pumps / AERN Series Pump

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Heavy duty gear pumps (Positive DisplacementRotary Twin gear Pumps) type AERN series pumps are useful for pumping and transfer of all kind of viscous Liquids and petroleum products.

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AERN Series

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INDEX Chapter Page No. 1 Introduction 1 2 Performance Characteristics 5 3 Operation 8 4 Shaft Sealing 16 5 Installation 17 6 Routine Maintenance Instructions 23 7 Trouble Shooting 24 8 Parts List 26 9 Assembly Disassembly Instructions 27 10 Dimension Drawing 35 11 Warrantee Test Certificate 36

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Introduction 1 1.1 General This instruction manual contains necessary information on the AERN series pumps having pump model of AERX AERN AERB and must be read carefully before installation service and maintenance. The manual must be kept easily accessible to the operator. Important The pump must not be used for other purposes than recommended and quoted for without consulting the company or your local distributor. Liquids not suitable for the pump can cause damages to the pump unit with a risk of personal injury. 1.2 Reception handling and storage 1.2.1 Reception Ÿ Remove all packing materials immediately after delivery. Check the consignment for damage Immediately on arrival and make sure that the name plate/type designation is in accordance with the Packing slip and your order. Ÿ In case of damage and/or missing parts report immediately to the carrier at once. Notify your supplier. Ÿ All pumps have the serial number stamped on a name plate. 1

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1 1.2.2 Handling Ÿ Check the weight of the pump unit. All parts weigh- ing more than 20 kg must be lifted using lifting slings and suitable lifting devices e.g. overhead crane or industrial truck. See section 10 Weights. Ÿ Never lift the pump unit with only two fastening points. Incorrect lift can cause personal injury and/or damage to the pump unit. Ÿ Always use two or more lifting slings. Make sure they are secured in such away as to prevent them from slipping. The pump unit should be in a straight fashion. Introduction 2

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1 1.2.3 Storage Ÿ After receipt of Material and inspection if the pump is not to be installed immediately the pump should be re-packed and placed in suitable places. The following points should be noted: Ÿ Cover the pump with corrosion inhibiting treatment material. Ÿ Storage location free from dust moist and vibration free place. Ÿ Rotate the pump unit by hand weekly to prevent jamming and damaged. 1.3 Safety Ÿ The pump must not be used for other purposes than recommended and quoted for without consulting the company or your local distributor. Always wear suitable safety clothing when handling the pump. Ÿ Anchor the pump properly before start-up to avoid personal injury and/or damage to the pump unit. Ÿ Check to see that the pump can be drained without injuring anyone and without contaminating the environment or nearby equipment. Introduction 3

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1 Ÿ Make sure that all movable parts are properly covered to avoid personal injury. Ÿ All electrical installation work must be carried out by electric personnel. Ÿ Improper installation can cause fatal injuries. Ÿ Dust liquids and gases that can cause overheating short circuits corrosion damage and fire must be kept away from motors and other exposed equipment. Ÿ If the pump handles liquids hazardous for person or environment some sort of container must be installed into which leakage can be led. All possible leakage should be collected to avoid contamination of the environment. Ÿ If the surface temperature of the system or parts of the system exceeds 60°C these areas must be marked with warning text reading "Hot surface" to avoid burns. Introduction 4

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2 2 Performance Characteristics 2.1 capacity Ÿ Drop of capacity with increase in pressure change of liquid 2.2 suction pressure The identification of suction pressure requirement is significant in any pump application. Ÿ Its calculation helps to find out the suction lift of the pump which enables to varify whether the pump will be able to self prime or not. Ÿ The suction pressure or termed as NPSH Net Positive Suction Head can be calculated by following equation NPSH Atmospheric pressure + Static Head - Static Lift viscosity STATIC LIFT ATMOSPHERIC PRESSURE STATIC HEAD Performance Characteristics 5

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2 2 2.3 Discharge pressure: Ÿ The discharge pressure shown in the delivery line is nothing but the overcoming of system pressure created by the resistance of the pipeline and the shearing force of the liquid. Thus it can be said that a gear pump does not develop pressure by its own but work against the system pressure exerted on it. 2.4 Power Consumption: Ÿ The power consumption of a rotary gear pump is mainly influenced by the differ- ential pressure exerted on it. Ÿ Factors effecting on power consumption as follows: 1. liquid viscosity 2. Sp. gravity of liquid. 3. Frictional loss. 4. operating temperature Performance Characteristics 6

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2 2.5 Effect of Viscosity: Ÿ Viscosity is that property of any liquid which tends to resist a shearing force. Ÿ The change in viscosity very much affects the perfor- mance characteristics of the pump i.e. capacity power consumption and speed. Ÿ At a defined set pressure the capacity of a pump slightly reduces with decrease in viscosity. This may be due to increase in internal slippage. Ÿ For a pump running at set speed for the desired capacity the power consumption increases with increase of liquid viscosity and decreases with the decrease of viscosity. Ÿ The above curves also show the effect of speed with reference to viscosity. POWER CONSUPTION SPEED 500 SSU 200 SSU ACTUAL THEORITICAL POWER CONSUPTION HYDRAULIC HP + VOLUMETRIC LOSSES POWER CONSUPTION AN NO LOAD FRICTIONAL LOSSES + MECHANICAL LOSSES OEFFERNTIAL PRESSURE CAPACITY THEORITICAL 500 SSU 200 SSU ACTUAL OEFFERNTIAL PRESSURE VOLUME TRIC LOSSES CAPACITY THEORITICAL 500 SSU 200 SSU SPEED ACTUAL Performance Characteristics 7

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3 3.1 Genral Gears Pump Casing Seal Drive Shaft Bearing R.V. Cover Relief Valve Front Cover Wear Plate Operation 8

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3 3.2 Operating Principal The external gear pump uses two identical gears rotating against each other one gear is driven by a motor and it in turn drives the other gear. Each gear is supported by a shaft with bearings on both sides of the gear. 1. As the gears come out of mesh they create expanding volume on the inlet side of the pump. Liquid flows into the cavity and is trapped by the gear teeth as they rotate. 2. Liquid travels around the interior of the casing in the pockets between the teeth and the casing it does not pass between the gears. 3. Finally the meshing of the gears forces liquid through the outlet port under pressure. Suction Suction Suction Discharge Discharge Discharge Operation 9

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3 3.3 Safety Relief valve: 3.3.1 Working Principle Ÿ valve protecting the pump against overpressure. Ÿ It can be installed on the pump or in the installation. Ÿ This safety relief valve limits the differential pressure Δp between suction and discharge not the maximum pressure within the installation. For example as media cannot escape when the discharge side of the pump is obstructed an over-pressure may cause severe damage to the pump. Ÿ The safety relief valve provides an escape path rerouting the media back to the suction side when reaching a specified pressure level. Ÿ The safety relief valve protects the pump against over-pressure only in one flow direction. Ÿ The safety relief valve will not provide protection against over-pressure when the pump rotates in the opposite direction. The positive displacement principle requires the installation of a safety relief Operation 10

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3 Ÿ properly. Ÿ When the safety relief valve is not installed on the pump other protections against overpressure have to be provided. Ÿ If the pump rotates in the opposite direction the safety relief valve or top cover must be disassembled and turned around by 180°. An open safety relief valve indicates that the installation is not functioning Discharge Suction Clockwise Direction Anti Clockwise Direction Discharge Suction Operation 11

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3 3.3.2 Safety Relief valve adjustment: Ÿ sure is performed at the factory. Ÿ To adjust the Safety Relief valve for oper- ating pressure proceed as follows : 1. Open the hex cap. 2. Tighten the ad. screw for increase set operating pressure or loose the ad. Screw for reduce the pump operating pressure. ▲ while increase of operating pressure power consumption of pump must not exceed the motor rated power. 3. Tighten the hex cap. Make sure that air must leakge from hex cap ad screw. Adjustment of the standard setting pres- Operation 12

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3 3.4 Check list for starting the pump: 3.4.1 Cleaning the pump Ÿ There may be residual mineral oil inside the pump deriving from the pump testing and the initially lubricating of the bearing bushes. Ÿ If the lubricating oil is not acceptable for the pumped liquid the pump should be cleaned thoroughly. 3.4.2 Supply and discharge line Ÿ Suction and discharge pipes are cleaned. Ÿ Suction and discharge pipes are checked for leaks. Ÿ Suction pipe is protected to entered foreign bodies. Operation 13

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3 3.4.3 Characteristics Ÿ Ÿ Pump model see name plate RPM working pressure effective power working temperature direction of rotation NPSHr etc. as per application 3.4.4 Electrical installation Ÿ Electric motor rating as per application data sheet Ÿ Electrical installation is complete as per local regulations Ÿ Motor voltage corresponds with mains voltage. Check terminal board. Ÿ Motor protection is adjusted properly. Ÿ Direction of motor rotation corresponds with direction of pump rotation. The characteristics of the pump unit and safety relief valve to be checked. Operation 14

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3 3.4.5 Safety relief valve Ÿ Ÿ Position of Safety relief valve according to direction of flow. Ÿ The set pressure of the safety relief valve is checked. 3.4.6 Drive Ÿ Alignment of pump motor gearbox etc. is checked 3.4.7 Protection Ÿ All guards and safety devices coupling rotating parts excessive temperature are placed. Safety relief valve on pump or in piping is installed Operation 15

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4 4. Shaft Seals: Differnets type of sealing options are aviallable as under. 1. Rubble oil seals 2. Gland Packing 3. Mechanical seal 1 7 6 4 3 5 2 Mech. Seal Mech. Seal Part List 1 2 3 5 4 L-Ring Rotary Face Stationary Face Stationary Outer Ring O"Ring 1 1 1 1 1 6 spring 1 7 Stationary Resting Part 1 Rubber Oil Seal Gland Packing Shaft Sealing 16

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5 5. Installation: 5.1 General: Pump performance is also dependence on pump installation. This manual gives basic information which is to be observed during installation of the pump. It is important to read this manual by responsible person before installation. 5.2 Location Foundation: Ÿ Locate the pump/pump unit as close as possible to the liquid source and if possible below the liquid supply level. The better the suction conditions the better the performance of the pump. Ÿ The pump should always be located where it is accessible for inspection main- tenance and repairing. Ÿ Every pump should be provide a good foundation by any strong structure to hold the pump rigid and to absorb any strain or shock that may be encountered. If a separate foundation is provided make it at least 4” wider and longer than base frame. Ÿ When the unit is placed on the foundation it should be leveled and checked for position against the piping layout and then fastened Owen. Installation 17

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5 5.3 Alignment: Ÿ get the required speed. Ÿ The coupling may be direct drive or belt drive. However direct drive is preferred over belt drive to reduce load on pump drive shaft and bearings. Ÿ During the operation shock load is produce due to pulsation. Therefore chose the coupling 1.5 time higher ration than normal constant load. Ÿ Pump and drive unit alignment must not more than as shown in fig. For running the pump it is required to couple pump with the drive unit to Installation 0.200mm Parralel alignment 18

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5 5.4 Piping: Ÿ nection ports of the pump and shortest possible. Ÿ If the fluid to be pumped is high viscous pressure losses in the suction and discharge lines may increase considerably. Other piping components like valves elbows strainers and filters also cause pressure losses. Ÿ Diameters length of piping and other components should be selected in such a way that the pump will operate without causing mechanical damage to the pump/pump unit taking into account the minimum required inlet pressure the maximum allowable working pressure and the installed motor power. Ÿ Check the tightness of the pipes after connection. Use piping with an equal diameter than the con- Strainer Pump Isolation valve Suction Installation 19

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5 5.4.1 Suction piping Ÿ level the inclining pipe should rise upwards towards the pump without any air pockets. Ÿ A too small diameter or a too long suction pipe a too small or blocked strainer will increase pressure losses so that the NPSHa NPSH available becomes smaller than the NPSH NPSH required. Cavitations will occur causing noise and vibrations. Mechanical damage to pump and pump unit is not excluded. Ÿ When a suction strainer or filter is installed pressure losses in the suction line must be checked constantly. Also check if the inlet pressure at the suction flange of the pump is still sufficiently high. Liquids should enter the pump from a level higher than the pump Installation 20

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5 5.4.2 Isolating valves Ÿ Isolation can be done by installing valves in suction and discharge lines. Ÿ These valves must have a cylindrical passage of the same diameter of the piping. Ÿ When operating the pump the valves must be opened completely. The output must never be regulated by means of closing valves in suction or discharge pipes.It must be regulated by changing shaft speed or by re-routing the media over a by-pass back to the supply tank. 5.4.3 Strainer Ÿ Foreign particles can seriously damage the pump. Avoid the entry of these particles by installing a strainer. Ÿ When selecting the strainer attention should be given to the size of the openings so that pressure losses are minimized. The cross-sectional area of the strainer must be three times that of the suction pipe. Ÿ Install the strainer in such a way that maintenance and cleaning are possible. Ÿ Make sure that the pressure drop in the strainer is calculated with the right viscosity. Heat the strainer if necessary to reduce viscosity and pressure drop. To allow proper maintenance it is necessary to be able to isolate the pump. Installation 21

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5 5.5 Electrical Installation. Ÿ Ÿ Input voltage frequency must be match with operating drive motor. Ÿ Install electrical overload safety device. Make sure that electrical connection must be properly. Installation 22

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6 6 Routine Maintenance instructions: Ÿ Ÿ Temperature of pump body should not exceed the operating temperature. Ÿ Check the leakage from suction and delivery line. Ÿ Check leakage from gland packing or shaft seal. Ÿ Check the air leakage from suction and relief valve. Ÿ Check the power consumption. Ÿ Check the temperature of the drive unit. Ÿ Check the alignment of the pump unit. Ÿ Check the axial and radial play of drive shaft Check the nose of pump Noise must not abnormal. Routine Maintenance instructions 23

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Suction lift too high. Lower pump or raise liquid level. Fluid pumped not compatible with materials used Use optional materials. No barrier system to prevent flow passing. Ensure discharge pipework higher than suction tank. Pump allowed to run dry. Ensure system operation prevents this. Fit single or double flushed mechanical seals. Fit flushed packed gland. Faulty motor. Check and replace motor bearings. Pumping element missing Fit pumping element. Relief valve leakage. Check pressure setting and re-adjust if necessary. Examine and clean sealing surfaces. Replace worn parts. Relief valve chatter Check for wear on sealing surfaces etc. Replace if necessary. Probable Causes Solutions Incorrect direction of rotation Reverse motor. Pump not Primed. Insufficient NPSH available. Cavitation Expel gas from suction line and pumping chamber and introduce fluid. Increase suction line diameter. Increase suction head. Simlify suction line configuration and resuce length. Reduce pump speed. Fluid vaporising in suction line. Increase suction line diameter. Increase suction head. Simplify suction line configuration and reduce length. Reduce pump speed. Air entering suction line. Remake pipework joints. Strainer or filter blocked. Service fittings. Fluid viscosity above rated figure. Increase fluid temperature. Decrease pump speed. Check seal face viscosity limitations. Fluid viscosity below rated figure. Decrease Fluid temperature. Increase pump speed. Fluid temp. above rated figure. Cool the pump casing. Reduce fluid temperature. Check seal face and elastomer temp. limitations. Fluid temp. below rated figure. Heat the pump casing. Increase fluid temperature. Unexpected solids in fuid. Clean the system. Fit strainer to suction line. Discharge pressure above rated figure Check for obstructions i.e. closed valve. Service system and change to prevent problem recurring. Simplify dicharge line to decrease pressure. Gland over-tightened Slacken and re-adjust gland packing. Gland under-tightened adjust gland packing. Seizure Packed gland leakage Mechanical seal leakage Problem No flow Under capacity Irregular discharge Low discharge pressure Pump will not prime Prime lost after starting Pump stalls when starting Pump overheats Motor overheats Excessive power absorbed Noise and vibration Pump element wear Pump speed above rated figure. Decrease pump speed. Pump speed below rated figure. Increase pump speed. Pump casing strained by pipework. Check alignment of pipes. Fit flexible pipes or expansion fittings. Support pipework. Flexible coupling misaligned. Check alignment and adjust mountings accrdingly. Insecure pump drive mountings. Fit lock washers to slack fasteners and re-tighten. Shaft bearing wear or failure. Refer to pump maker for advice and replacement parts. Insufficient gearcase lubrication. Refer to pump makers instructions. Metal to metal contact of pumping element. Check rated and duty presures. Refer to pump maker. Worn pumping element. Fit new components. Trouble Shooting Trouble Shooting 7 24

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10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4 5 6 7 8 9 25 29

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8 Parts List AERN Pump with Needle Roller bearing as shaft Bearings AERX Pump with Needle Roller bearing as shaft Bearings V-seal AERB Pump with Bush bearing as shaft Bearings 26 PARTS NO. DESCRIPTIONS AERN PUMP AERX PUMP AERB PUMP Drain oil plug Bolt gland cover washer gland cover Gland cover Shaft Seal Bolt Front cover Washer front cover Dowel Oil inlet plug Shaft Bearing V - seal Wear Plate Body Packing Gears Stator shaft Rotor shaft Bearing Sleeve Snap Ring Washer Gear Shaft Assembly Bolt Gear Shaft assembly Pump Casing R. V. Cover Hex Cap Relief Valve Adjustment screw R. V. Plug Spring Sheet R. V. Spring R. V. Piston PARTS NO. DESCRIPTIONS AERN PUMP AERX PUMP AERB PUMP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Front Cover

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9 9.1 General Ÿ tioning high repair costs and long-term inoperability. Ÿ Disassembly and assembly may only be carried out by trained personnel. Such personnel should be familiar with the pump and follow the instructions below. Ÿ ANI Engineers is not liable for accidents and damage of the pump or pump unit for faulty assembly. Ÿ Remove the pump from the operation. 9.2 Dissemble Instructions. 9.2.1 Remove gland cover Ÿ unscrew hex bolt no.2 washer Ÿ Remove gland cover Insufficient or wrong assembly and disassembly can lead to the pump malfunc- 2 4 Assembly Disassembly Instructions 27

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9 9.2.2 Remove Front cover Ÿ Ÿ Open front cover Ÿ Remove body packing Ÿ Remove dowel if inside the front cover. Ÿ Remove V-seal if pump model AERX Ÿ Remove shaft bearing Needle roller or bush Ÿ Remove shaft seal from front coverno.5 9.2.3 Remove R.V. cover assembly Ÿ unscrew hex bolt no.6 washer Ÿ Remove R.V. cover Ÿ Remove body packing Ÿ Remove dowel if inside the R.V. cover. Ÿ Remove V-seal if pump model AERX Ÿ Remove shaft bearing Needle roller or bush unscrew hex bolt no.6 washer 6 6 5 28 Assembly Disassembly Instructions

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9 9.2.4 Relief valve disassembly Ÿ find problem in relief valve operation. Ÿ unscrew hex cap no.23 Ÿ unscrew Adjustment screw Ÿ Open relief valve plug Ÿ Remove spring sheet Ÿ Remove spring Ÿ Remove piston. Open relief valve assembly if 23 Assembly Disassembly Instructions 29

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9 9.2.5 Remove Gear shaft assembly Ÿ Ÿ Remove rotor and stator gear shaft assembly. 9.2.6 Gear shaft disassembly Ÿ Unscrew bolts no. 20 Ÿ Remove washers no. 19 Ÿ Remove gears Bearing Sleeves from shafts use the plastic block to avoid shaft must not damage from press force. Remove wear plates SUPPORT PRESS Assembly Disassembly Instructions 30

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9 9.3 Assembly Instructions. 9.3.1 Gear shaft assembly Ÿ hand second is left hand in pair Ÿ Insert bearing sleeve both side replace if damage Ÿ Insert washer and screw the bolt no. 20 9.3.2 Gear shaft assembly Ÿ Assembled rotor stator gear shaft assembly in pump casing. Ÿ Assembled wear plate replace wear plates if wear out. Ÿ Replace gasket body packing with seal- ant. Insert Gears in the shafts one gear is right SUPPORT PRESS Assembly Disassembly Instructions 31

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9 9.3.3 Relief valve assembly Ÿ Ÿ Place spring in piston. Ÿ Place spring sheet on spring Screw the relief valve plug. Ÿ Screw the adjustment screw as previously. Ÿ Screw the hex cap over the adjustments screw. 9.3.4 Relief valve cover assembly Ÿ Fit the bearing in Relief valve cover. replace bearing if damaged Ÿ Fit the V-seal in Relief valve cover if pump model is AERX. replace the V-seal if damaged Ÿ Fit the relief valve assembly with pump casing. Ÿ Screw the bolt no. 6 with washer Place piston in relief valve cover. 6 Assembly Disassembly Instructions 32

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9 9.3.5 Front cover assembly Ÿ bearing if damaged Ÿ Fit the V-seal in front cover if pump model is AERX. replace the V-seal if damaged Ÿ Fit the front cover assembly with pump casing. Ÿ Screw the bolt no. 6 with washer 9.3.6 Pump Rotation Check: Ÿ Checks the drive shaft rotates smoothly then fit all dowel and tighten the bolt no. 6. Fit the bearing in front cover. replace 6 5 Assembly Disassembly Instructions 33

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9 9.3.7 Gland cover Fitting: Ÿ replace the seal if damaged Ÿ Push the gland cover in to the gland box. Ÿ Screw the bolt no 2. With washer. each bolt should b tighten equally Fit the shaft seal in gland cover. 2 4 Assembly Disassembly Instructions 34

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10 AE-050-S-M-L AE-100-S-M-L AE-150-S-M-L AE-200-S-L AE-250-S-L AE-300-S-L AE-400-S-L AE-500-S-L AE-600-S-L AE-601-S-L 239 271 318 359 419 461 554 615 690 749 150 160 180 200 220 240 280 295 340 360 110 130 145 165 190 220 255 280 318 357 80 90 105 110 130 160 180 200 220 240 100 110 130 150 160 220 270 300 350 380 91 100 119 133 163 166 189 215 215 230 80 90 100 112 132 160 180 200 225 250 69.0 74.0 80.0 89.5 100.0 131.0 145.0 160.0 178.0 200.0 12 12 14 14 15 20 22 25 26 28 08 10 10 12 15 18 18 19 20 22 4 4 4 4 4 4 4 4 4 4 89 108 127 152 178 190 229 254 279 279 16 16 16 19 19 19 19 22 22 22 60 79 98 121 140 152 190 216 241 241 22 25 25 40 40 53 53 60 70 70 30 30 40 50 55 60 65 85 95 100 11.5 15.0 21.0 24.0 27.0 32.0 37.0 47.0 52.0 57.0 4 5 6 8 8 10 10 14 16 16 13.0 17.0 23.5 27.0 30.0 35.0 40.0 50.5 58.0 61.0 SHAFT DIMENSIONS FLANGE DIMENSIONS MOUNTING DIMENSIONS OVERALL DIMENTIONS Model A F H 2 B C E H H 1 T D ø 1 No. OF HOLE No. OF SIZE P.C.D. L L 1 Dø P O D ø 2 Kg. Weight 8.0 14.0 22.5 28.0 43.0 59.0 82.0 150.0 175.0 190.0 35 Dimension Drawing A C E H 2 L H F B H 1 D Ø 2 T 4 Nos D Holes 1 Ø L 1 DØ Q P

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36 11

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Design-Printed : Ketan Pithva 98255 17118

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